Drive Axles 73 1973-74 AUSTIN MARINA ‘Austin Marina (1973-74) DESCRIPTION Rear axles are hypoid design with center line of pinion set below centerline of ring gear. The axle shafts, pinion ond differential assemblies can be serviced without removing axle ‘trom vehicle. All differential adjustments are performed using shims. No adjustment for axle shaft end play is necessary, AXLE RATIO & IDENTIFICATION ‘Only one basic axle design is used on these models. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth, REMOVAL & INSTALLATION AXLE SHAFTS & BEARINGS 1) With rear of vehicle raised and wheel removed, remove foxle shaft nut and washer. Remove screws retaining brake ‘drum ond remove drum. Withdraw rear hub from axle shaft Using suitable tool. Disconnect handbrake cable ond broke pipe. Remove nuts, washers ond bolts retaining brake backplate to axle housing 2) Note installed position of drip lip in relation to brake slave cylinder and remove oil catcher and backplate. assembly Remove rear hub oil seal and hovsing assembly. Remove ol seal from housing using suitable tool. Remove axle shatt key fond ploce container under axle to collect oil spillage Withdrow oxle shaft from housing, using suitable puller. Remove inner oil seal and press bearing from oxle shaft 3) Pack beoring with lithium based grease ond dip new oil Seal in light oil before reassembling, Install new oil seal with lip of seal facing inwards. Press bearing onto axle shaft until dimension from bearing to threaded end of axle shaft is to specifications. Continue assembling in reverse of disossembly Using @ new rear hub joint washer and using “Loctite LT 270" for equivalent on axle shoft nut PINION FLANGE & SEAL 1) Roise ond support rear of vehicle. Mark propeller shaft and pinion flanges for correct realignment. Disconnect propeller Shaft ond remove flange nvt split pin. Retain flonge using suitable tool and remove nut and washer. 2) Place container under flange to collect cil spillage ond remove flange and oll seal, To install, reverse removol procedure noting the following: Soak new seal in light oil for fone hour before installing. Install seal with lip of seal facing inwards DIFFERENTIAL CARRIER Remove both axle shafts and mark differential pinion ond propeller shoft for proper realignment on assembly Disconnect propeller shaft. Ploce container under axle ‘ossembly to collect il and remove nuts and washers retaining carrier to oxle housing. Remove carrer. To reinstall, reverse removal procedure, ving @ new gasket ond witebe gosket OVERHAUL DISASSEMBLY 1) With carrier removed, mount unit upright in @ vise and mark bearing cops for correct reassembly. Remove bearing cap bolts, washers and caps, Astemble suitable oxle stretcher (186-131) on unit casing and stretch unit case by tightening turnbuckle three or four flats until differential carrier can be levered out and bearing shims and cops removed. CAUTION "To aveid damaging case, do not spread any more than necessary. Maximum stretch is .008" (.20 mm). Do not pry ‘agains stretcher. 2) Remove gear corrier bearing caps and mark ring gear ond carrier to ensure correct replacement. Remove ring gear retaining bolts and ring gear. Drive out pinion shaft locking pin, then drive out pinion shaft. Remove pinion gears and thrust washers. Remove differential gears ond thrust washers. Remove drive flange nut cotter pin and drive flange nut. Using suitable puller, remove drive flange. 3) Press out drive pinion and remove pinion bearing shims ond ‘spacer. Using suitable press tools, remove inner bearing from Binion, Remove pinion head washer and drift out pinion outer beoring cup, bearing ond oil seal. Drift out pinion inner beor- ing cup, INSPECTION CClean and inspect all components for wear or damage. Ring ‘and pinion gears, differentiol bearings ond pinion beorings must be replaced as matched sets. REASSEMBLY & ADJUSTMENT Side Bearing Preload — 1) Instll differential beoring cones jn geor carrier using suitable tool. Install two differential ‘gears in cartier, ensuring each thrust washer is correctly positioned. Position two pinion gears, one each side of carrer fond mesh them with diferentiol gears. Using an oxle shaft in- Diol Indicator CHECKING RUNOUT & TOTAL SIDE FLOAT ‘ipo 200 Rapa ema Campa14 Drive Axles 1973-74 AUSTIN MARINA (Cont.) serted in a differential gear, turn gears and ensure two pinions rotate into mesh and align with pinion shaft hole in Earrie. Install pinion shaft 2) Press each pinion firmly into mesh with differential gears fond assess required pinion thrust washer thickness required to ‘ochieve ZERO backlash. Remove pinion shaft ond pinions ond install thrust washers. Reinstall pinion gears and shafts with ‘thrust washers and check that zero backlash exists. Lubricate ‘components and install pinion shah locking pin and secure by peening metal of differential carrier 3) Clean ring gear mounting ond carrier face and install ring ‘gear, tighten bolts. Assemble carrier bearing cups to bearings ‘ond position assembly in case; do not install bearing shims Install bearing cops in correct position. Using diol indicator ‘ond suitable adopters, ensure that ring gear runout does not ‘exceed specifications. Remove bearing cops and press differential bearing cups onto bearings ond move carrier ‘ossembly to one side of case. Zero dial indicator ond move corrier assembly fully in opposite direction. The indicator reading should be noted for future reference as “Total Side Float”. Remove differential assembly from cate. Drive Pinion Depth — 1) Install inner and outer pinion bearing cups to case using suitable tool. Install pinion inner beating to dummy pinion (186-191 M). NOTE — Dummy pinion incorporates stondord pinion head washer of .077" (1.95 mm) thickness. Oil bearing ond install dummy pinion, outer bearing, tool spacer, washer and nut. Tighten nut gradually until bearing preload specification is obtained Clean dummy pinion head ond postion dial indicator gavge foot of tool 186-191 on dummy head and zero indicator, Dummy Pinion CHECKING PINION DEPTH 2) Move dil indicotor over center of one differential bearing bore and note reading. Repeot for opposite bearing bore. ‘Average these two measurements and perform the following calevlation: EXAMPLE ‘Average of bore measurements £002" (.051 mm) PLUS dummy pinion washer allowance... 077" (1.956 mm) Required size of pinion head washer... .079" (2.007 mm) If the etched marking on pinion face is "N" (normal), no change to above dimension is requried. If etched marking is postive (+), reduce size of required pinion washer by amount ‘marked. I etched marking is negative (—], increase size of required pinion washer by amount marked. Remove dummy pinion and remove inner bearing from dummy pinion. Pinion Bearing Preload — 1) Place selected pinion head ‘washer on pinion and install inner bearing using suitable tools Oil bearing ond install pinion in cose. Instoll bearing spacer, chamfered end towards drive flange, Install shims oll ond in stall outer bearing. Install drive flange washer ond nut Gradvally tighten nut, but do not exceed torque specification, ‘ond check preload during tightening operation. 2) Rotate flonge to settle beoring and check preload with flange aut tightened to specifications. If prelood is high, in- crease shim thickness. If preload is low, decrease shim thickness, NOTE — .001" shim thickness equals approximately 4 INCH lbs. (4.8 emkg) preload. Remove drive flange nut and flange. Soak new oil eal in oil for one hour and then install seal. Install drive flange, washer ond nut and tighten flange ‘ut, Install new cotter pin Diol Indicator Adopter CHECKING BACKLASH Adjusting Backlash ~ 1) Place bearing cups on differential bearing and install carrier in case. Position diol indicator with svitable adopters on ring gear side of case. Move ring gear {ully into mesh with pinion and zero indicator on reer of ring ‘gear. Move ring gear ond carrier in opposite direction until bearing ring gear side is butted in housing. The indicated ‘measurement should be noted os the “In-Out” mesh clearance, ‘ipo 200 Rapa ema CampaDrive Axles 1973-74 AUSTIN MARINA (Cont.) Dy 3AS03 Adopter CHECKING "IN-OUT" MESH CLEARANCE 2) Perform the following coleulation: EXAMPLE "In-Out" mesh clearance®. 025" (.63 mm) MINUS Specified backlash (005" (.13 mm) Required ring gear side shim pack. 020" (.50 mm) "Total Side Float" is (060° (1°52 mm) MINUS ring geor side shim pack. (020° ('50 mm) Required shim pack opposite ring gear... -040" (1.02 mm) © — Value from 2) above © — Volue from 2} under “Side Bearing Prelood” ‘Add @ value of .002" (.51 mm) to each shim pack colculet ‘obove for preload. 3) Stretch cose specified amount and from calculations made ‘above, select required shim pack. Install differential ossembly jn cate with shim packs. Loosen case stretcher and remove. Install bearing cops 0: originelly marked and tighten bolts. Rotote pinion to setile differential bearings and position dial indicator using suitable adapters to measure ring gear backlash, Measure backlash af several locations, it must be to specifications. If not, interchange shims from side to side to ‘achieve specified backlash. NOTE — A movement of .002" {.05 mm) shim thickness from one bearing fo the other will vary backlash by about .002" (.05 mm). Reinstall differential ‘ossembly in tear axle housing ‘AXLE ASSEMBLY SPECIFICATIONS Bearing-to-Threaded End of Axle Shaft. 2.84" (69.94 mm) Ring Gear Runou (003" (.076 mm) Pinion Bearing Preload.... 15-18 INCH tbs. (17-21 emkg) Ring Gear Backlash (005+.001" .13:4.02 mm) TIGHTENING SPECIFICATIONS Application Fr. Lbs. (mkg) Brake Backplate Nuts 223) Axle Shatt Nut 105 (14.5), Carrier Mounting Nuts 23) Pinion Flange Not... 90(12.4) ‘ipo 200 Rapa ema Campa